Shock absorbing container

ABSTRACT

A shock absorbing container assembly for packaging articles, including an outer container, a sheet member, and an article container. In the closed configuration, the outer container includes an inner top surface and an opposed inner bottom surface that are substantially fixedly spaced apart in a vertical axis. The sheet member has a bottom surface and at least one preformed foldable portion that is folded away from the bottom surface terminating at a free distal edge. The free distal edge bears against the top surface of the outer container when receiving vertically directed forces transmitted by the top surface. The article container for receiving articles is disposed inside the outer container and includes a plurality of intersecting walls. Vertically directed forces transmitted by the sheet member are received by at least two of the walls that have upper ends bearing against the bottom surface of the sheet member and lower ends bearing against the bottom surface of the outer container. The walls, by intersecting with each other, support one another to maintain the walls upright so that the walls are enabled to support the vertically directed forces transmitted by the sheet member.

FIELD OF INVENTION

[0001] The present invention relates to the field of containers and moreparticularly to a shock absorbing container.

BACKGROUND OF INVENTION

[0002] When stacked or handled, a container can experience forces orshocks in the side-to-side or front-to-back (“horizontal”) direction orin the up or down (“vertical”) direction. Fragile articles stored in thecontainer, such as circuit boards, can be damaged as a result of forcesor shocks. Thus, there is a need to protect articles stored in thecontainer from forces and shocks.

[0003] To protect articles, a cellular structure can be placed in theinterior of a container, such as the exemplary cellular structure shownin FIG. 1. FIG. 2 shows the cellular structure of FIG. 1 placed within acontainer. A number of articles may be placed in the shown cellularstructure; typically, one article per cell. Generally, articles are notplaced in the outer cells. The outer cells serve to protect articles inthe inner cells from horizontal forces or shocks. The cellular structureby itself, however, does not provide protection from vertical forces orshocks.

[0004] In order to protect the contents from vertical forces and shocks,a polymer foam cushion may be employed at the top or the bottom of thecontainer. The cellular structure shown in FIGS. 1-2 has a recessedrectangular area that is adapted to receive a rectangular polymer foamcushion, such as the one shown in FIG. 3. FIG. 4 shows, incross-section, the container and cellular structure of FIGS. 1-2 whichadditionally includes the polymer foam cushion of FIG. 3. Polymer foam,however, is expensive. In addition, recycling polymer foam iscomplicated and recycling facilities are not always available. Further,containers that employ polymer foam cushions may be difficult toassemble.

[0005] FIGS. 5-6 show another method for protecting the contents of acontainer from vertical forces and shocks. FIG. 5 shows an exemplaryfolded corrugated board that may be employed inside a container. FIG. 6shows a cross-sectional view of a container having a pair of foldedcorrugated boards. The dashed line represents one or more articles inthe container. Each folded corrugated board includes a vertical sectionparallel to a container wall that remains stationary, an end sectionthat projects over the article at an angle above the horizontal, and afold or score at the junction of the two sections. When the lidexperiences a vertical force or shock, the end section bends inwardabout the fold providing cushioning. As the shown folded corrugatedboard bends down, however, the end section can contact the articles inthe container. This can result in the force or shock being transferreddirectly to the articles. Moreover, containers that employ foldedcorrugated board may be difficult to assemble.

[0006] Accordingly, there is a need for shock absorbing container inwhich articles packaged within the container are protected from verticalforces and shocks.

BRIEF SUMMARY OF THE INVENTION

[0007] Disclosed herein is a shock absorbing container. Within the scopeof the invention is a shock absorbing container assembly for packagingone or more articles, including an outer container, a sheet member, andan article container. The outer container has a closed configuration forshipping the articles. In the closed configuration, the outer containerincludes an inner top surface and an opposed inner bottom surface thatare substantially fixedly spaced apart in a vertical axis. The sheetmember has a bottom surface and at least one preformed foldable portion.The preformed foldable portion is folded away from the bottom surface ofthe sheet member and terminates at a free distal edge. The free distaledge bears against the top surface of the outer container when receivingvertically directed forces transmitted by the top surface. The articlecontainer is disposed inside the outer container and is for receivingarticles. The article container includes a plurality of intersectingwalls so that, when receiving vertically directed forces transmitted bythe sheet member at least two of the walls have upper ends bearingagainst the bottom surface of the sheet member and lower ends bearingagainst the bottom surface of the outer container. The walls, byintersecting with each other, support one another to maintain the wallsupright so that the walls are enabled to support the vertically directedforces transmitted by the sheet member.

[0008] In one preferred embodiment, the sheet member is formed ofcorrugated paperboard.

[0009] The foregoing and other objectives, features, and advantages ofthe invention will be more readily understood upon consideration of thefollowing detailed description of the invention, taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0010]FIG. 1 illustrates a prior art cellular structure.

[0011]FIG. 2 illustrates the cellular structure of FIG. 1 within acontainer.

[0012]FIG. 3 illustrates a prior art polymer foam cushion.

[0013]FIG. 4 is a cross-sectional view the polymer foam cushion of FIG.3 disposed within the cellular structure and container of FIG. 2.

[0014]FIG. 5 illustrates a prior art folded corrugated board.

[0015]FIG. 6 is a cross-sectional view of a pair of the foldedcorrugated boards of FIG. 5 disposed within a container.

[0016]FIG. 7 illustrates a shock absorbing container assembly thatincludes an outer container and an article container having notched andreverse notched partitions according to the present invention.

[0017]FIG. 8 illustrates the article container of FIG. 7.

[0018]FIG. 9 shows a reverse notched partition of the article containerof FIG. 8

[0019]FIG. 10 shows a notched partition of the article container of FIG.8.

[0020]FIG. 11 illustrates an alternative preferred embodiment of anouter container.

[0021]FIG. 12 illustrates a sheet member according to the presentinvention.

[0022]FIG. 13 illustrates the sheet member of FIG. 12 in a foldedarrangement.

[0023]FIG. 14 illustrates an alternate embodiment of a sheet memberaccording to the present invention.

[0024]FIG. 15 illustrates the sheet member of FIG. 14 in a foldedarrangement.

[0025]FIG. 16 illustrates two of the sheet members of FIG. 12 disposedwithin an article container according to the present invention.

[0026]FIG. 17 is a cross-sectional view of the sheet members and articleholding container of FIG. 16.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0027] This detailed description of a preferred embodiment is organizedas follows: First, the exemplary prior art packaging methods shown inFIGS. 1-6 are described in detail. Second, the present invention isdiscussed with reference to FIGS. 7-17. Finally, the meaning of some ofthe terms and phrases used herein are discussed.

[0028]FIG. 1 illustrates an exemplary cellular structure 20. FIG. 2shows the cellular structure 20 of FIG. 1 within a container 22. Anumber of articles may be placed in the shown cellular structure 20;typically, one article per inner cell 24. Generally, articles are notplaced in the outer cells 26. The cellular structure 20 does not provideprotection from vertical forces or shocks.

[0029]FIG. 3 illustrates a polymer foam cushion 28 that may be employedat the top or the bottom of a container to protect the contents fromvertical forces and shocks. The cellular structure shown in FIGS. 1-2has a recessed rectangular area 30 that is adapted to receive thepolymer foam cushion 28. Polymer foam is expensive and can be difficultto recycle.

[0030]FIG. 4 shows, in cross-section, the cellular structure 20, thecontainer 22, and the polymer foam cushion 28 disposed in recessed area30.

[0031]FIG. 5 illustrates an exemplary folded corrugated board 32 thatmay be employed inside a container 40. The folded corrugated board 32includes a vertical section 34, an end section 36, and a fold 38 at thejunction of the two sections.

[0032]FIG. 6 shows a cross-sectional view of a container 40 having apair of folded corrugated boards 32. The dashed line represents anarticle 42 within the container. The vertical sections 34 of each foldedcorrugated board 32 are parallel to the side walls of the container 40.The end section 36 projects over the article 42 at an angle above thehorizontal. When the top side 46 receives a vertical force or shock, theend section 36 bends down about the fold 38 in the direction of arrows48. When the end section 36 bends down, it can contact the article 42.If end section 36 does contact the article 42, the vertical force orshock will be transferred to the article 42.

[0033] Turning now to FIGS. 7-16, preferred embodiments of a shockabsorbing container assembly according to the present invention areillustrated. The present invention provides protection from verticalforces and shocks without relying on polymer foam. Moreover, verticalforces or shocks are not transferred to the article. The shock absorbingcontainer assembly includes three components: an outer container, asheet member, and an article container.

[0034]FIG. 7 illustrates a preferred embodiment of a shock absorbingcontainer assembly 50 that includes one preferred embodiment of an outercontainer 52 having four side walls 54, a bottom side 56, and a lid 58.The side walls 54 define a vertical (“y”) axis. The outer container 52also includes an inner bottom surface 62 (not shown). The inner bottomsurface 62 is opposite bottom side 56. The shown lid 58 is removable.Alternatively, the lid 58 may be hingedly attached to the outercontainer 52. As such, the shock absorbing container assembly 50 has twoconfigurations: a closed configuration when the lid 58 is disposed as atop side of the outer container 52 and an open configuration when thelid 58 is not so disposed. In the closed configuration, the outercontainer 52 additionally includes an inner top surface 60. The innertop surface 60 is opposite a top side 64 of the lid 58. The inner topsurface 60 and the inner bottom surface 62 are substantially fixedlyspaced apart in the vertical axis by a distance defined by the height ofthe side walls 54. One preferred embodiment of an article container 66is disposed within the outer container 52.

[0035]FIG. 8 illustrates the article container 66. The article container66 has a plurality of intersecting walls. The intersection of one wallwith another maintains both walls in an upright position. Each wallprovides support to the other by means of the coupling provided by theintersection. For example, if a vertical force or shock is exerted on anupper end of a wall, the wall will maintain its upright position throughthe support provided by the intersection. Of course, there is a limit tothe amount of support that can be provided and normally the intersectionof two corrugated board walls will not prevent crushing should asufficient vertical force be applied.

[0036] The shown article container 66 is assembled from two types ofpartitions that are shown in FIGS. 9-10. FIG. 9 shows a reverse notchedpartition 68. FIG. 10 shows a notched partition 70. Generally, anarticle container 66 includes two or more parallel reverse notchedpartitions 68 and at least two parallel notched partitions 70. Notches72 in the reverse notched partition 68 are received in appropriatenotches 74 of the notched partition 70. When assembled, the reversenotched and notched partitions 68, 70 are at right angles to each other.There is generally one more reverse notched partition 68 than the totalnumber of articles. Referring to FIG. 8, articles are placed in cells74, but not in the outer cells 76 as these cells are intended to protectthe articles from horizontal forces or shocks (along the x and z axis).

[0037] Other embodiments for forming the plurality of intersecting wallsof the article container 66 are contemplated. In an alternativeembodiment, a single sheet of material may be folded to form two or moreintersecting walls. In yet another embodiment, the partitions can beformed by the use of adhesive material, such as glue. Moreover, theintersecting walls can be made from a plurality of parts or cut-outs.

[0038] The article container 66 also includes a sheet member holdingrecess 78 that is formed from a plurality of reverse notched partitions68. Referring to FIG. 9, the sheet member holding recess 78 on eachreverse notched partitions 68 has an upper end 80 and a pair of inclinededges 82. An acute angle 84 defines the relation between the upper end80 and the inclined edge 82.

[0039]FIG. 11 illustrates an alternative preferred embodiment of anouter container 52 shown in cut-away. The outer container 52 includes aninner top surface 60, an inner bottom surface 62, and side walls 54 thatdefine a vertical (“y”) axis. The inner top surface 60 and the innerbottom surface 62 are substantially fixedly spaced apart in the verticalaxis as defined by the height of the side walls 54. The outer container52 may have an open and closed configuration that is provided by a sidewall 54 that is removable.

[0040] FIGS. 12-13 illustrate two views of a sheet member 86. In FIG.12, the sheet member 86 is in the form of a corrugated board blankhaving two fold lines 88. The fold lines 88 define a bottom surface 90and two preformed foldable portions 92. The fold lines 88 may be lineson or scores in the corrugated board blank. Additionally, each preformedfoldable portion 92 has a free distal edge 94. FIG. 13 illustrates thesheet member 86 in an arrangement in which each preformed foldableportion 92 has been folded upward along its respective adjacent foldline 88. As shown, each preformed foldable portions 92 projects awayfrom the bottom surface 90 at an angle 96 of approximately 30 degrees.The shown angle 96 is exemplary and any angle between 1 and 89 degreesis contemplated.

[0041] The fold lines 88 are preferably provided at the location shownin FIGS. 12, 13. However, the fold lines 88 may be closer to or fartheraway from the free distal edge 94. The location of the fold line 88 isdefined by the length “l” of the preformed foldable portion 92. Inaddition, while it is essential that the sheet member have at least onepre-folded portion, it is preferable that the sheet member have at leasttwo pre-folded portions.

[0042]FIGS. 14, 15 illustrate a sheet member 98 having an alternativeembodiment of the preformed foldable portion 100. In the shownembodiment, the preformed foldable portion 100 is defined within thesheet member 98. In FIG. 14, the sheet member 98 has three cut lines 102that are cut into it and a transverse fold line 104. The material isseparated along the cut lines 102 and folded about the fold line 104 tocreate a preformed foldable portion 100, as shown in FIG. 15.

[0043]FIG. 16 illustrates the sheet member 86 disposed within the sheetmember holding recess 78 of an article container 66. The sheet memberholding recess 78 captures the sheet member 86 thereby preventingside-to-side movement of the sheet member with respect to the articlecontainer 66. Referring to FIGS. 9 and 16, the sheet member holdingrecess 78 is preferably provided with an upper end 80, inclined edges82, and acute angles 84 that define the relation between the upper end80 and the inclined edges 82. The inclined edges 82 confine thepreformed foldable portions 92 with respect to vertical movement. Thebottom surface 90 of the sheet member 86 contacts the upper end 80 ofthe reverse notched partition 68. The article container 66 also has aplurality of lower ends that contact the bottom surface of the outercontainer 52 when the article container 66 is positioned within theouter container 52.

[0044] The article container 66 has an optional second sheet member 86disposed within a lower sheet member holding recess 108. When thearticle container 66 is positioned within the outer container 52, thesecond sheet member holding recess 108 and the second sheet member 86will be disposed adjacent to the inner bottom surface 58 of the outercontainer 52. This optional configuration protects against verticalforces and shocks from below the shock absorbing container assembly 50.

[0045]FIG. 17 shows, in cross-section, the article holding container 66together with the two of the sheet members 86 of FIG. 16 disposed in anouter container 54.

[0046] When the article container 66 is disposed in the outer container52 the free distal edges 94 may be in direct contact or close proximityto the inner top surface 60. When the outer container experiences avertical force or shock, the inner top surface 60 contacts the freedistal edges 94 and the preformed foldable portions 92 bend inward aboutfold line 88 providing cushioning. The preformed foldable portion 92 andthe fold line 88 together effectively act as a spring. The strength ofthe spring is proportional to the length “l” of the preformed foldableportion 92.

[0047] The intended meaning of some of the terms and phrases used hereinis discussed below.

[0048] The phrase “sheet member” 86, 98 refers to both the flat blankarrangements shown in FIGS. 12, 14 and the folded arrangements shown inFIGS. 13, 15. The sheet member can be shipped and stored in the flatblank arrangement for later assembly into the folded arrangement whenneeded. While the shown sheet member 86 is preferably made of corrugatedboard, it may be made from plastics, composites, or other materials.

[0049] The phrase “article holding container” refers to both thepartitions shown in FIGS. 9-10 and the assembled article containers,such as those shown in FIGS. 8 and 16. The article holding container canbe shipped and stored as unassembled partitions for later assembly intothe article containers of FIGS. 8 and 16 when needed.

[0050] The phrase “free distal end” 94, with reference to thetermination point of the pre-folded portion of the sheet member, meansthat the free distal end has enough freedom of movement to provide shockabsorption. Complete freedom of movement of the pre-folded portion isnot required. Any range of motion sufficient that allows the free distalend 94 to move in response to a shock is sufficient.

[0051] The word “vertical” is used herein only to provide a frame ofreference for describing the invention. It will be appreciated that theinvention can be easily adapted to provide shock absorption against aforce or shock originating in any direction. For example, an articlecontainer with a sheet member holding recess (and a sheet memberdisposed therein) in a side wall will provide shock absorption in thehorizontal direction.

[0052] The word “shipping,” with reference to the outer container 52 ina closed configuration, refers to any situation in which the containerassembly may be subjected to forces or shocks.

[0053] The phrase “fixedly spaced apart,” with reference to the innertop surface and the inner bottom surface of the outer container, meansthat the top and bottom surfaces are spaced apart by a defined distancethat does not vary in a substantial way under normal conditions. Thephrase is not intended to contemplate that the surfaces are spaced apartby a precisely defined distance at all times. For example, a verticalforce exerted downward on the lid 58 may cause it to bend. Similarly, avertical force exerted downward on the lid 58 may result in adeformation, e.g., a dent. It is contemplated that an inner top orbottom surface may bend or be deformed and still be “fixedly spacedapart” from each other as this phrase is used herein.

[0054] The terms and expressions that have been employed in theforegoing specification are used as terms of description and not oflimitation, and are not intended to exclude equivalents of the featuresshown and described or portions of them. The scope of the invention isdefined and limited only by the claims that follow.

What is claimed is:
 1. A shock absorbing container assembly forpackaging one or more articles, comprising: an outer container definingat least a closed configuration for shipping the articles, said outercontainer including an inner top surface and an opposed inner bottomsurface that is substantially fixedly spaced apart in a vertical axisfrom said top surface in said closed configuration; a sheet memberhaving a bottom surface and at least one preformed foldable portionfolded away from said bottom surface of said sheet member, said foldableportion terminating at a free distal edge and bearing against said topsurface of said outer container when receiving vertically directedforces transmitted by said top surface; and an article containerdisposed inside said outer container and for receiving the articles,said article container comprising a plurality of intersecting walls fordisposition in said outer container so that, when receiving verticallydirected forces transmitted by said sheet member, at least two of saidwalls have upper ends bearing against the bottom surface of said sheetmember and lower ends bearing against said bottom surface of said outercontainer, wherein by intersecting, said walls support one another tomaintain said walls upright so that said walls are enabled to supportthe vertically directed forces transmitted by said sheet member.
 2. Thecontainer assembly of claim 1, wherein said sheet member is formed ofcorrugated paperboard.
 3. The container assembly of claim 1, whereinsaid sheet member includes two preformed foldable end portions forfolding away from said bottom surface of said sheet member, saidfoldable portions terminating at respective free distal edges forbearing against said top surface of said outer container.
 4. Thecontainer assembly of claim 3, wherein said sheet member is formed ofcorrugated paperboard.
 5. The container assembly of claim 1, whereinsaid article container includes at least four vertical walls, whereineach wall intersects two other walls at substantially 90 degree angles.6. The container assembly of claim 5, wherein said article containerincludes at least five vertical walls to provide at least two separatecompartments.
 7. The container assembly of claim 6, wherein at least twoof said vertical walls include cut-outs adapted for receiving said sheetmember.
 8. The container assembly of claim 7, wherein said sheet memberis formed of corrugated paperboard.
 9. The container assembly of claim8, wherein said sheet member includes two preformed foldable endportions for folding away from said bottom surface of said sheet member,said foldable portions terminating at respective free distal edges forbearing against said top surface of said outer container.
 10. A shockabsorbing container assembly for packaging one or more articles;comprising: an outer container defining at least a closed configurationfor shipping the articles, said outer container including an inner topsurface and an opposed inner bottom surface that is substantiallyfixedly spaced apart in a vertical direction from said top surface insaid closed configuration; a sheet member having a bottom surface and atleast one preformed foldable portion for folding away from said bottomsurface of said sheet member, said foldable portion terminating at afree distal edge for bearing against said top surface of saidouter-container, for receiving and at least partially absorbingvertically directed forces transmitted by said top surface; and anarticle container for disposition inside said outer container and forreceiving the articles, said article container comprising a plurality ofintersecting walls for disposition in said outer container so that atleast two of said walls have upper ends for bearing against the bottomsurface of said sheet member and lower ends for bearing against saidbottom surface of said outer container, wherein by intersecting, saidwalls are adapted to support one another to maintain said walls uprightso that said walls are enabled to support vertically directed forcestransmitted by said sheet member.
 11. The container assembly of claim10, wherein said sheet member is formed of corrugated paperboard. 12.The container assembly of claim 10, wherein said sheet member includestwo preformed foldable end portions for folding away from said bottomsurface of said sheet member, said foldable portions terminating atrespective free distal edges for bearing against said top surface ofsaid outer container.
 13. The container assembly of claim 12, whereinsaid sheet member is formed of corrugated paperboard.
 14. The containerassembly of claim 10, wherein said article container includes at leastfour vertical walls, wherein each wall intersects two other walls atsubstantially 90 degree angles.
 15. The container assembly of claim 14,wherein said article container includes at least five vertical walls toprovide at least two separate compartments.
 16. The container assemblyof claim 15, wherein at least two of said vertical walls includecut-outs adapted for receiving said sheet member.
 17. The containerassembly of claim 16, wherein said sheet member is formed of corrugatedpaperboard.
 18. The container assembly of claim 17, wherein said sheetmember includes two preformed foldable end portions for folding awayfrom said bottom surface of said sheet member, said foldable portionsterminating at respective free distal edges for bearing against said topsurface of said outer container.
 19. A shock absorbing containerassembly for packaging one or more articles, the container assemblyhaving an outer container defining at least a closed configuration forshipping the articles, the outer container including an inner topsurface and an opposed inner bottom surface that is substantiallyfixedly spaced apart in a vertical axis from the top surface in theclosed configuration, the container assembly comprising: a sheet memberhaving a bottom surface and at least one preformed foldable portion forfolding away from said bottom surface of said sheet member, saidfoldable portion terminating at a free distal edge for bearing againstsaid top surface of said outer container, for receiving and at leastpartially absorbing vertically directed forces transmitted by said topsurface; and an article container for disposition inside said outercontainer and for receiving the articles, said article containercomprising a plurality of intersecting walls for disposition in saidouter container so that at least two of said walls have upper ends forbearing against the bottom surface of said sheet member and lower endsfor bearing against said bottom surface of said outer container, whereinby intersecting, said walls are adapted to support one another tomaintain said walls upright so that said walls are enabled to supportvertically directed forces transmitted by said sheet member.
 20. Thecontainer assembly of claim 19, wherein said sheet member is formed ofcorrugated paperboard.
 21. The container assembly of claim 19, whereinsaid sheet member includes two preformed foldable end portions forfolding away from said bottom surface of said sheet member, saidfoldable portions terminating at respective free distal edges forbearing against said top surface of said outer container.
 22. Thecontainer assembly of claim 21, wherein said sheet member is formed ofcorrugated paperboard.
 23. The container assembly of claim 19, whereinsaid article container includes at least four vertical walls, whereineach wall intersects two other walls at substantially 90 degree angles.24. The container assembly of claim 23, wherein said article containerincludes at least five vertical walls to provide at least two separatecompartments.
 25. The container assembly of claim 24, wherein at leasttwo of said vertical walls include cut-outs adapted for receiving saidsheet member.
 26. The container assembly of claim 25, wherein said sheetmember is formed of corrugated paperboard.
 27. The container assembly ofclaim 26, wherein said sheet member includes two preformed foldable endportions for folding away from said bottom surface of said sheet member,said foldable portions terminating at respective free distal edges forbearing against said top surface of said outer container.